Client

Smart Green Shipping

Location

Hunterston Quay, West Coast of Scotland

Scope

In-situ machining and on-site machining of wind turbine foundation studs to enable wingsail test rig installation

The Challenge

Smart Green Shipping approached us to support the delivery of their first FastRig wingsail, a key milestone in advancing low-carbon shipping technology. To reduce both project cost and programme duration, the client made the strategic decision to reuse a redundant onshore wind turbine foundation at Hunterston Quay as the base for a wingsail test rig.

The wind turbine base comprised steel-reinforced concrete with a large number of cast-in threaded studs. While structurally sound, the studs had suffered significant corrosion and mechanical damage during the turbine’s decommissioning. For the test rig to be securely installed, the studs needed to be:

• Machined to a uniform height

• Re-machined on the outer diameter

• Stripped of the existing damaged thread

• Re-threaded to a new M39 thread, maintaining 120 mm of usable thread length

Compounding the challenge, the site was remote and fully exposed, with:

• No fixed electrical power

• No crane or lifting support

• Limited access

• Harsh coastal environmental conditions

Our Solution

Leveraging our extensive experience in on-site machining and in-situ machining, we developed a bespoke solution tailored specifically for the constraints of the site.

Our engineering team designed a modular machining system that could be securely mounted directly onto the existing foundation. The system allowed a custom-machining plate to be installed, enabling the machine to slide across the plate and machine six studs at a time. This approach significantly reduced setup time and improved productivity.

Key elements of the solution included:

• In-situ machining of all studs without removal or heavy lifting

• Equipment capable of operating from a 110V generator, eliminating the need for site power

• A low-lift, low-handling methodology to maximise safety

• Flexible fixing methods, using:

  • Adjacent serviceable studs where available

  • Rawl bolts installed directly into the concrete base by our engineers where required

This innovative setup ensured accurate, repeatable machining across all studs while maintaining tight tolerances in challenging offshore-style conditions.

The Result

Despite the exposed location and logistical limitations, the project was:

• Completed on time

• Delivered within budget

• Executed safely and efficiently in a live coastal environment

The successful completion of the in-situ machining works enabled Smart Green Shipping to install their test rig, complete validation testing, and progress their FastRig wingsail to market.

Value Delivered

• Extended the life of existing infrastructure through precision on-site machining

• Eliminated the need for stud removal or foundation replacement

• Reduced project cost and schedule risk

• Enabled rapid testing and deployment of innovative clean-shipping technology

Technical Expertise You Can Rely On

This project demonstrates our ability to deliver complex in-situ machining solutions in demanding environments. From bespoke tooling design to precision thread reinstatement, our team brings deep technical knowledge, adaptability, and proven field experience to every project.

To see the success of this project in action, please follow the link below.

https://smartgreenshipping.com/pressandmedia/2025/5/29/sgs-fastrig-and-fastroute-validated-by-success-of-sea-trials